Electromagnetic interference splice shield

ABSTRACT

A splice device for electromagnetically sealing a junction or bond between a plurality of cables is provided. A first and second cable each has a conductive core wire, an inner insulation, a braided sleeve, and an insulating cover. The junction or bond fixes and electrically connects the core wire of the second cable to the core wire of the first cable. A plurality of ferrules overlays the braided sleeve and the insulating cover of the first cable and the braided sleeve and the insulating cover of the second cable. A plurality of ring collars overlays the plurality of ferrules and is fixed to the plurality of ferrules. A splice cover or shield overlays the first cable, second cable, plurality of ferrules, and plurality of ring collars and electromagnetically seals the junction/bond between the core wires of the first cable and the second cable.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. non-provisional patentapplication Ser. No. 14/667,116, filed Mar. 24, 2015, which isincorporated herein by reference in its entirety.

FIELD

The present disclosure relates to wire harness splitter assemblies orsplice devices, and specifically to improved electromagneticinterference splice shields for such splice devices.

BACKGROUND

This section provides background information related to the presentdisclosure and is not necessarily prior art.

Splitter assemblies or splice devices in wire harnesses are generallyused to split a single electrical conduit or wire into multipleelectrical wires or combine multiple electrical wires into a singleelectrical wire. Often, these splitter assemblies come in the form ofjunction blocks that are capable of splitting two wires into four ormore wires. Junction blocks contain a large number of parts and thus canrequire complicated assembly processes and can be very expensive.Further, junction boxes are relatively bulky and occupy significantspace, presenting design challenges and packaging issues.

Additionally, electrical wire connections are often located in thevehicle's chassis and are therefore exposed to external influences suchas weather, wind, moisture, and contaminants from the surroundingenvironment. The effect on wire connection points is that over time theycan become corroded; generate increased resistance, and potentiallyundesired contact between the wires.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

In certain aspects, a splice device is provided that includes a spliceshield for enclosing a junction between a first electrically conductiveconduit and a second electrically conductive conduit. Each of aplurality of ferrules respectively overlays a portion of the firstelectrically conductive conduit and a portion of the second electricallyconductive conduit. Each of a plurality of ring collars respectivelyoverlay and is fixed to the plurality of ferrules. The splice shield isfixed to the plurality of ring collars and serves to electromagneticallyshield the junction from an external environment.

The splice device may further include a junction that is an ultrasonicweld joint formed by bonding the first electrically conductive conduitto the second electrically conductive conduit by ultrasonic welding.

The splice device may further include a first electrically conductiveconduit that comprises a first conductive core, a first inner insulativelayer, a first braided sleeve, and a first external insulative cover anda second electrically conductive conduit that comprises a secondconductive core, a second inner insulative layer, a second braidedsleeve, and a second external insulative cover. The plurality offerrules may each respectively overlay a portion of the first externalinsulative cover, the first braided sleeve, and the first innerinsulative layer and a portion of the second external insulative cover,the second braided sleeve, and the second inner insulative layer.

The splice device may further include a first electrically conductiveconduit that defines a first exposed region where the first innerinsulative layer, the first braided sleeve, and the first externalinsulative cover are removed from the first conductive core and a secondelectrically conductive conduit that defines a second exposed regionwhere the second inner insulative layer, the second braided sleeve, andthe second external insulative cover are removed from the secondconductive core. The junction may be formed between the first exposedregion and the second exposed region.

The splice device may further include a portion of the first externalinsulative cover on the first electrically conductive conduit that isremoved to expose the first braided sleeve, a portion of the firstbraided sleeve that is removed to expose the first inner insulativelayer, and a portion of the first inner insulative layer that is removedto expose the first conductive core thereby defining the first exposedregion, and a portion of the second external insulative cover on thesecond electrically conductive conduit that is removed to expose thesecond braided sleeve, a portion of the second braided sleeve that isremoved to expose the second inner insulative layer, and a portion ofthe second inner insulative layer that is removed to expose theconductive core thereby defining the second exposed region.

The splice device may further include a portion of a first of theplurality of ferrules positioned over the first external insulativecover at a location adjacent to a first exposed braided sleeve on thefirst conduit. The first exposed braided which is folded over the firstof the plurality of ferrules. A first of the plurality of ring collarsis disposed over the folded first exposed braided sleeve. Thus, thesplice device includes the first ring collar disposed over the firstferrule that is disposed on the first external insulative cover at thelocation, where the first braided sleeve is sandwiched between the firstring collar and the first ferrule. Further, a second of the plurality offerrules is positioned over the second external insulative cover at alocation adjacent to a second exposed braided sleeve. The second exposedbraided sleeve on the second electrically conductive conduit is foldedover the second of the plurality of ferrules, and a second of theplurality of ring collars that is disposed over the folded secondexposed braided sleeve. Thus, the splice device includes the second ringcollar disposed over the second ferrule disposed on the second externalinsulative cover at the location, where the second braided sleeve issandwiched between the second ring collar and the second ferrule.

The splice device may further include a first and second of theplurality of ring collars that is crimped to the respective first andsecond of the plurality of ferrules. The first folded exposed braidedsleeve may be disposed between the first of the plurality of ringcollars and the first of the plurality of ferrules, and the secondfolded exposed braided sleeve may be disposed between the second of theplurality of ring collars and the second of the plurality of ferrules.

The splice device may further include a plurality of ring collars thatis clamped or crimped over the plurality of ferrules.

The splice device may further include a protective cover disposed overthe plurality of ferrules and the plurality of ring collars and beneaththe splice shield. The protective cover protects the junction frommoisture and external contaminants.

The splice device may further include a splice shield that is formedfrom metal.

The splice device may further include a plurality of ferrules and aplurality of ring collars that are respectively formed from metal.

The splice device may further include a first electrically conductiveconduit and a second electrically conductive conduit that arehigh-voltage shielded wires. The first electrically conductive conduithas a cross-sectional area of greater than or equal to about 70 mm². Thesecond electrically conductive conduit has a cross-sectional area ofgreater than or equal to about 50 mm².

The splice device may further include a third electrically conductiveconduit. The junction connects the first electrically conductiveconduit, the second electrically conductive conduit, and the thirdelectrically conductive conduit.

In certain other aspects, a high-voltage splice device is provided thatmay include a first high-voltage electrically conductive conduit havinga first conductive core and defining a first exposed region and a secondhigh-voltage electrically conductive conduit having a second conductivecore and defining a second exposed region. The first exposed region isfixed via a bond to the second exposed region. A splice shield is fixedto the first high-voltage electrically conductive conduit and the secondhigh-voltage electrically conductive conduit at a location covering thebond. The splice shield mechanically secures the first and secondhigh-voltage electrically conductive conduits together, whileelectromagnetically shielding the bond from an external environment.

The high-voltage splice device may further include a bond that is anultrasonic weld.

The high-voltage splice device may further include a plurality offerrules each respectively overlaying a portion of the firsthigh-voltage electrically conductive conduit adjacent the first exposedregion and a portion of the second high-voltage electrically conductiveconduit adjacent the second exposed region and a plurality of ringcollars each respectively overlaying and fixed to the plurality offerrules.

The high-voltage splice device may further include a first high-voltageelectrically conductive conduit having a first external insulativecover, a first braided sleeve, and a first inner insulative layerdisposed around the first conductive core external to the first exposedregion. A second high-voltage electrically conductive conduit may have asecond external insulative cover, a second braided sleeve, and a secondinner insulative layer disposed around the second conductive coreexternal to the second exposed region. The plurality of ferrules eachrespectively overlays a portion of the first external insulative cover,the first braided sleeve, and the first inner insulative layer and aportion of the second external insulative cover, the second braidedsleeve, and the second inner insulative layer. The plurality of ringcollars is respectively disposed over the folded first exposed braidedsleeve and the folded second exposed braided sleeve.

In yet other aspects, a high-voltage splice device is provided thatincludes a first high-voltage electrically conductive conduit having afirst conductive core and defining a first exposed region and a secondhigh-voltage electrically conductive conduit having a second conductivecore and defining a second exposed region. The first exposed region isfixed via a junction to the second exposed region. A plurality offerrules each respectively overlay a portion of the first electricallyconductive conduit and a portion of the second electrically conductiveconduit. A splice shield encloses the junction between the firstelectrically conductive conduit and the second electrically conductiveconduit. The splice shield mechanically secures the first and secondhigh-voltage electrically conductive conduits together andelectromagnetically shields the junction from an external environment. Aplurality of ring collars each respectively overlays and is fixed to theplurality of ferrules. The splice shield is fixed to the plurality ofring collars.

In certain other aspects, a method of assembling a high-voltage splicedevice is provided that may include forming a first exposed region in afirst electrically conductive conduit and forming a second exposedregion in a second electrically conductive conduit. Then, a portion ofthe first electrically conductive conduit and a portion of the secondelectrically conductive conduit are overlaid with a plurality offerrules. The plurality of ferrules are overlaid and fixed with aplurality of ring collars. The first exposed region and the secondexposed region are mechanically and electrically joined in a junction.The junction between the first electrically conductive conduit and thesecond electrically conductive conduit is then enclosed andelectromagnetically shielded using a splice shield fixed to theplurality of ring collars.

The method of assembling a high-voltage splice device may furtherinclude mechanically and electrically joining the first exposed regionand the second exposed region by ultrasonic welding.

The method of assembling a high-voltage splice device may furtherinclude overlaying a portion of a first external insulative cover, afirst braided sleeve, and a first inner insulative layer in the firstelectrically conductive conduit with the plurality of ferrules andoverlaying a portion of a second external insulative cover, a secondbraided sleeve, and a second inner insulative layer in the secondelectrically conductive conduit with the plurality of ferrules.

The method of assembling a high-voltage splice device may furtherinclude removing the first inner insulative layer, the first braidedsleeve, and the first external insulative cover from the firstelectrically conductive conduit to define the first exposed region andremoving the second inner insulative layer, the second braided sleeve,and the second external insulative cover from the second electricallyconductive conduit to define the second exposed region.

The method of assembling a high-voltage splice device may furtherinclude positioning a first of the plurality of ferrules over the firstexternal insulative cover at a location adjacent to the exposed firstbraided sleeve, folding the first exposed braided sleeve on the firstconduit over the first of the plurality of ferrules, and arranging afirst of the plurality of ring collars over the folded first exposedbraided sleeve and positioning a second of the plurality of ferrulesover the second external insulative cover at a location adjacent to theexposed second braided sleeve, folding the second exposed braided sleeveon the second electrically conductive conduit over the second of theplurality of ferrules, and arranging a second of the plurality of ringcollars over the folded second exposed braided sleeve.

The method of assembling a high-voltage splice device may furtherinclude crimping the first and second of the plurality of ring collarsto the respective first and second of the plurality of ferrules, wherethe first folded exposed braided sleeve is disposed between the first ofthe plurality of ring collars and the first of the plurality offerrules, and the second folded exposed braided sleeve is disposedbetween the second of the plurality of ring collars and the second ofthe plurality of ferrules.

The method of assembling a high-voltage splice device may furtherinclude clamping or crimping the plurality of ring collars over theplurality of ferrules.

The method of assembling a high-voltage splice device may furtherinclude positioning a protective cover over the plurality of ferrulesand the plurality of ring collars and beneath the splice shield andprotecting the junction from moisture and external contaminants.

The method of assembling a high-voltage splice device may furtherinclude connecting a third electrically conductive conduit with thefirst electrically conductive conduit and the second electricallyconductive conduit.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIG. 1 is an elevated perspective view of a center splice deviceaccording to certain aspects of the present disclosure;

FIG. 2 is an environmental view of the center splice device of FIG. 1;

FIG. 3 is a top view of primary and secondary conduits or cablesaccording to certain aspects of the present disclosure;

FIG. 4 is a top view of the primary and secondary conduits or cables ofFIG. 3;

FIG. 5 is a top view of wiring of the center splice device of FIG. 1;

FIG. 6 is a top view of wiring of the center splice device of FIG. 1;

FIG. 7 is a top view of a splice shield of the center splice device ofFIG. 1;

FIG. 8 is a top view of the center splice device of FIG. 1;

FIG. 9 is a top view of another splice shield of the center splicedevice;

FIG. 10 is a top view of the center splice device incorporating thesplice shield of FIG. 9; and

FIG. 11 is a top view of the center splice device of FIG. 1 covered witha protective heatshrink tube cover.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting.

FIGS. 1-9 illustrate a center splice device according to various aspectsof the present disclosure. Referring to FIGS. 1, 2 and 8, a centersplice device 10 joins a plurality of conduits (either positive ornegative), such as cables 14, that are connected together in a junctionor bond to simplify assembly and reduce product assembly cycle timeresulting in labor and equipment cost reduction. The junction 18 is apoint where wires of the conduits 14 are electrically and mechanicallycoupled together, which could be a bond. Splice device 10 includes asplice shield, or electromagnetic (EMI) shield, 18 that mechanically andelectrically connects the cables 14, while electromagnetically shieldingand protecting the bond between cables 14 from an external environment.Splice device 10 further includes a plurality of ring collars 26 and aplurality of inner ferrules 30 that are used to bond, insulate, andprotect the plurality of cables 14 (FIG. 8).

Referring specifically to FIG. 3, the plurality of cables 14 may includea primary cable 34 and a secondary cable 38. In certain variations, anyof cables 14 may respectively be high-voltage cables, which typicallymeans that the cable is rated to a voltage capacity of greater than orequal to about 2 kV. By way of example, the primary cable 34 may be ahigh-voltage (HE) shielded cable that has a cross-sectional area ofgreater than or equal to about 70 mm². The secondary cable 38 may be ahigh-voltage (HE) shielded cable that has a cross-sectional area ofgreater than or equal to about 50 mm². While the primary cable 34 isdescribed as a 70 mm² HE cable and the secondary cable is described as a50 mm² HE cable, it is understood that these cables are not limited tothese sizes. Other embodiments may utilize any size primary andsecondary cable. Further, the primary cable and secondary cable may bethe same size cable or may be different size cables.

In certain variations, the plurality of cables 14 may be insulatedconduits, such as insulated high-voltage wires. By way of example, theprimary cable 34 may further include a conductive core wire 42, overwhich is disposed an inner insulative layer 46, a braided sleeve 50, andan external insulative cover 54. The secondary cable 38 may likewisefurther include a conductive core wire 58, an inner insulative layer 62,a braided sleeve 66, and an external insulative cover 70. The conductivecore wires 42, 58 may be formed of electrically conductive materials,such as copper or aluminum. The conductive conduits or core wires 42, 58may be a solid conductive core or a plurality of distinct strands orwires, as well. The inner insulative layers 46, 62 may be formed fromconventional electrically insulating materials, such as cross-linkedelastomer (AXLE), cross-linked polyethylene (PEP), thermoplasticelastomers (TPE), polyethylene (PE), or other known insulatingmaterials. The braided sleeves 50, 66 may be formed from a material suchas a tinned copper braid shield, a copper mesh, saturated polyestermonofilaments, polyethylene terephthalate (PET), fiberglass,combinations thereof, or other braided sleeve materials. The externalinsulative covers 54, 70 may be formed of an electrically insulatingmaterial, such as cross-linked elastomer (XLE), extruded polyethylene(PE), polyvinylchloride (PVC), or other insulating materials, by way ofexample.

Secondary cable 38 may be connected, coupled, or bonded to the primarycable 34 at junction 16, described in more detail below. Connecting,coupling, or bonding the secondary cable 38 to the primary cable 34electrically and mechanically joins the secondary cable 38 and theprimary cable 34 together. A terminal end 106 of secondary cable 38 maybe joined, for example, via a bonding process, to a first exposed region86 of primary cable 34 through ultrasonic welding (e.g., a splice nuggetin FIGS. 5 and 8, represented schematically by box 16 in FIGS. 6 and11), described in more detail below. While ultrasonic welding isdescribed to bond the secondary cable 38 to the primary cable 34, it isunderstood that in other embodiments any bonding method may be used tosecure the secondary cable 38 to the primary cable 34, such as, forexample, resistance, laser welding, and splice terminal crimp.

With reference to FIGS. 3 and 4, and in preparation for bonding, aportion 72 of the external insulative cover 54 may be removed from theprimary cable 34 between a first region 74 and a second region 76 of theprimary cable revealing the braided sleeve 50. For example only, theportion 72 may be approximately 85 millimeters (mm) for a 1500 mm longprimary cable 34. A portion 78 of the braided sleeve 50 may be removedfrom the primary cable 34 at the center of the portion 72, revealing theinner insulative layer 46. For example only, the portion 78 may beapproximately 65 mm for a 1500 mm primary cable 34. A portion 82 of theinner insulation 46 may be removed from the primary cable 34 at thecenter of the portion 78, revealing the conductive core wire 42,creating a center strip or first exposed region 86 of core wire 42 forbonding. For example only, the portion 82 and center strip 86 may beapproximately 25 mm in length.

In further preparation for bonding, a portion 90 of the externalinsulative cover 70 of the secondary cable 38 may be removed from afirst end 94, opposite a second region 96, revealing the braided sleeve66. For example only, the portion 90 may be approximately 60 mm for a750 mm long secondary cable 38. A portion 98 of the braided sleeve 66may be removed from the first end 94 of the secondary cable 38,revealing the inner insulative layer 62. For example only, the portion98 may be approximately 50 mm for a 750 mm long secondary cable 38. Aportion 102 of the inner insulation may be removed from the first end 94of the secondary cable 38, revealing the conductive core wire 58 andcreating and defining an end strip, a second exposed region, or terminalend region 106 for bonding. For example only, the portion 102 and endstrip 106 may be approximately 15 mm in length.

Referring to FIG. 4, and before bonding the end strip or terminal endregion 106 of secondary cable 38 to center strip or first exposed region86 of primary cable 34, ring collars 26 and inner ferrules 30 may beplaced on the primary cable 34 and secondary cable 38. The innerferrules 30 may be cylindrical sleeves formed from metal that strengthenthe primary and secondary cables 34, 38 and prevent the externalinsulative covers 54, 70 from splitting or wearing near the portions 72,90 that were removed. The inner ferrules 30 can be fixed to respectivelocations on the primary and secondary cables 34, 38 near or adjacent toeither the exposed region 86 or terminal end region 106. Morespecifically, the inner ferrules 30 can be fixed on the first region 74or second region 76 of primary cable 34 adjacent to portions 72, 78, and82 or adjacent to the portions 90, 98, and 102 of the first end 94 ofsecondary cable 38. For example only, the inner ferrules 30 may be of ametal, such as brass, aluminum, copper, and the like. In someembodiments, the inner ferrules 30 may also be made of metal materials,such as an unplated brass, plated brass (plated with tin, silver, orgold), zinc plated carbon steel, or other strengthening material. Twoferrules 30 may be placed over the external insulative cover 54 on theprimary cable 34, with one ferrule 30 on each side of the portion 72that was removed from the external insulative cover 54. In someembodiments, one of the ferrules on the primary cable 34 may include aflanged portion 110 that acts as a stop when installing the spliceshield 18, as further discussed below. A single ferrule 30 may be placedover the insulating cover 70 on the secondary cable 38 adjacent to theportion 90 that was removed from the external insulative insulatingcover 70.

The ring collars 26 may be circular rings or cylindrical sleeves formedfrom metal that retain the inner ferrules 30 and braided sleeves 50, 66in place on the external insulative covers 54, 70. The ring collars 26may further retain and position the splice shield 18 over the bond 16 inthe cables 34, 38 (FIG. 8). For example only, the ring collars 26 may beof a brass, aluminum, copper, or other metal. Two ring collars 26 may beplaced over the inner insulation 46 on the primary cable 34, with onering collar 26 on each side of the portion 82 that was removed from theinner insulation 46. In some embodiments, one of the ring collars 26 onthe primary cable 34 may include a flanged portion 114 that acts as astop when installing the splice shield 18, as further discussed below. Asingle ring collar 26 may be placed over the inner insulation 62 on thesecondary cable 38 adjacent to the portion 102 that was removed from theinner insulation 62.

Exposed portions 118 of braided sleeves 50, 66 adjacent to the externalinsulative covers 54, 70 are folded back over the inner ferrules 30placed over the external insulative covers 54, 70. Referringadditionally to FIG. 5, the ring collars 26 are positioned over foldedexposed portions 120 and a hexagonal (HEX) crimp is applied to the ringcollars 26 to retain the ring collars 26, folded exposed portions 120,and ferrules 30 in place on the external insulative covers 54, 70 of theprimary cable 34 and secondary cable 38.

Now referring to FIG. 5, the exposed terminal end region 106 ofconductive core wire 58 of the secondary cable 38 may be bonded to theexposed region 86 of core wire 42 of the primary cable 34. In someembodiments, the end strip 106 may be bonded to the center strip 86through ultrasonic welding. In ultrasonic welding, the end strip 106 andcenter strip 86 are held together under pressure and high-frequencyultrasonic acoustic vibrations are locally applied to create thesolid-state weld or bond 16 (e.g., a splice nugget formed by compressionof wire strands together via high frequency vibration caused by theultrasonic energy). While the bond 16 is described as formed fromultrasonic welding, it is understood that the bond 16 could be formedfrom any bonding method, for example only, through splice terminalcrimp, resistive welding, or other bonding methods.

After bonding the terminal end region 106 of secondary cable 38 toexposed region 86 of the primary cable 34, the first region 74 of theprimary cable 34 may extend in a first direction from the bond 16 andthe second region 76 of the primary cable 34 and the second region 96 ofthe secondary cable 38 may extend in a second, opposite, direction fromthe bond 16. Thus, the first region 74 of the primary cable 34 may be ona first side 122 of the bond 16 and the second region 76 of the primarycable 34 and the second region 96 of the secondary cable 38 may be on asecond side 126 of the bond 16. In certain alternative variations, thesplice device 10 may join a plurality of cables. For example only, thesplice device may join three (3) or more cables, where there may be aprimary cable with a first terminal end, a secondary cable with a secondterminal end, and a tertiary cable with a third terminal end, where eachof the first, second, and third terminal ends are all joined together.

Referring to FIG. 6, once the exposed terminal end region 106 ofconductive core wire 58 of the secondary cable 38 is fixed to theexposed region 86 of core wire 42 of the primary cable 34 at bond 16, aprotective cover, which may be a heatshrink tube, 130 is inserted overthe bond 16 by sliding the heatshrink tube 130 over the first end 74 ofthe primary cable 34 and over the bond 16. The heatshrink tube 130 maybe approximately 50 mm long for a center strip approximately 25 mm inlength and an end strip approximately 15 mm in length bonded together.The heatshrink tube 130 may be formed from a thermoplastic material suchas, for example, a polyolefin, fluoropolymers (such as fluorinatedethylene propylene (FEP), polytetrafluoroethylene (PTFE), orpolyvinylidene fluoride (PVDF), polyvinylchloride (PVC), neoprene,silicone elastomer or fluoroelastomers, such as VITON™ commerciallyavailable from E.I. duPont de Nemours and Co. The protective heatshrinktube 130 thus provides abrasion resistance and environmental sealingprotection for the bond 16 and preventing exposure to moisture and othercontaminants. The heatshrink tube 130 is centered over the bond 16, andheat is applied to the heatshrink tube 130 to shrink the tube such thatit wraps tightly around the bond 16. While the splice device 10 isdescribed as having a protective cover 130 covering the bond, inalternative embodiments, the protective cover 130 could be eliminatedand the EMI splice shield 18 could be placed over the connection beforea protective cover.

Referring to FIGS. 7-10, the splice shield 18 is inserted over the bond16 and heatshrink tube 130 to protect and seal the center splice device10. When installed, the splice shield 18 electrically connects andmechanically connects the primary cable 34 and secondary cable 38 bycooperating with the ring collars 26. Further, splice shield 18electromagnetically insulates the bond 16. A first end 134 of the spliceshield 18 is slid over the first region 74 of the primary cable 34. Thesplice shield 18 is inserted over the primary cable 34 and bond 16 untila second end 138 of the splice shield 18 contacts the flanged portion110 of the ferrule 30 on the primary cable 34. The second end 138 of thesplice shield 18 may include a rolled-under or lip portion 140 thatcontacts the flanged portion 110 of the ferrule 30 and prevents thesplice shield 18 from sliding further over the primary cable 34. Inalternative embodiments, the splice shield 18 may be inserted over theprimary cable 34 and bond 16 until the second end 138 of the spliceshield 18 contacts the flanged portion 114 of the ring collar 26 on theprimary cable 34. In these alternatives, the rolled-over portion or lipportion 140 may contact the flanged portion 114 of the ring collar 26 toprevent further movement of the splice shield 18 over the primary cable34. Thus, the first end 134 of the splice shield 18 is positioned overthe ring collars 26 on the first region 76 and terminal end 96 of theprimary cable 34 and secondary cable 38 and the second end 138 of thesplice shield 18 is positioned over the ring collar 26 on the firstregion 74 of the primary cable 34.

The splice shield 18, or EMI shield, may be formed of a metal such as,for example, aluminum, copper, brass (alloys comprising copper andzinc), tin, combinations thereof, or other types of metal suitable forsuch purposes. Thus, the metal splice shield 18 may be clamped, crimped,welded, or otherwise metallurgically bonded, to the ring collars 26. Inother embodiments, the splice shield 18 may be formed of a non-metallicmaterial such as ceramic or plastic and may be adhered to the ringcollars 26 via an adhesive/sealant material to seal the bond 16.

The splice shield 18 is formed such that there is a dual port side 142on the first end 134 for receiving the second region 76 of the primarycable 34 and the end 96 of the secondary cable 38 and a single port 146on the second end 138 for receiving the first region 74 of the primarycable 34. The dual port side 142 on the first end 134 may include anindented portion 150 between the ports to define a first port 154 and asecond port 158. The first port 154 may receive the second end 76 of theprimary cable 34 and the second port 158 may receive the second end 96of the secondary cable 38. If the primary cable 34 is a larger gaugethan the secondary cable 38, the first port 154 may be a larger diameterthan the second port 158. If the primary cable 34 is the same gauge asthe secondary cable 38, the first port 154 may be the same diameter asthe second port 158.

Referring to FIGS. 7 and 8, the splice shield 18 may be formed such thatthe second port 158 is offset from the single port 146 and the firstport 154. The first port 154 and single port 146 are aligned such thatthe primary cable 34 may extend through the first port 154 and singleport 146 without unnecessary bending or kinking of the primary cable 34.The second port 158 is offset from the single port 146 and the firstport 154 in order to receive the secondary cable 38 that is bonded tothe primary cable 34. Referring to FIGS. 9 and 10, and in alternativeembodiments, the splice shield 18A has a single port 146 that may becentered between the first port 154 and the second port 158. In thisembodiment, the primary cable 34 extends through the first port 154 andsingle port 146, slightly bending within the splice shield 18 as theprimary cable 34 transitions between aligning with the first port 154and aligning with the single port 146. Like the first port 154, thesecond port 158 is also offset from the single port 146 and receives thesecondary cable 38 that is bonded to the primary cable 34 at bond 16.

Referring again to FIGS. 7-10, the splice shield 18 is crimped over thering collars 26 such that it provides a weather and environment sealover the bond 16. Any crimping device (not illustrated) may be used tocrimp the splice shield 18 over the ring collars 26.

Now referring to FIG. 11, a second heatshrink tube 162 may be appliedover the splice shield 18 to further provide weather and environmentseal over the splice shield 18 and the bond 16. The heatshrink tube 162may be a heatshrink cross-linked Polyolefin cable breakout boot (CCB)providing optimum resistance against common fluids and solvents within apredetermined thermal range (for example only, −55° C. up to 100° C.).The heatshrink tube 162 may further be 1X2 CCB heatshrink tubing. Heat(for example only, 135° C.) is applied to the second heatshrink tube 162to shrink the tube such that it wraps tightly around the splice shield18.

The resulting center splice device 10 is sealed from external elementsand moisture, but provides a robust, improved design configurationhaving fewer components than a traditional junction block. Such a splicedevice is particularly advantageous for use with high-voltage, highcross-sectional area conduit assemblies. The center splice device 10 isless expensive to produce from two perspectives: (1) the center splicedevice 10 has fewer components than a traditional junction block, thushaving streamlined assembly processes, and (2) the materials used in thecenter splice device 10 are less expensive than the traditional junctionblocks. The center splice device 10 is much smaller than traditionaljunction blocks and, thus, can be more easily integrated into thevehicle and wiring harness systems. Thus, the center splice device 10provides effective electromagnetic (EMI) shielding in a compact,inexpensive package.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

We claim:
 1. A method of assembling a high-voltage splice devicecomprising: forming a first exposed region in a first high-voltageelectrically conductive conduit having a first conductive core; forminga second exposed region in a second high-voltage electrically conductiveconduit having a second conductive core; overlaying a portion of the ofthe first high-voltage electrically conductive conduit and a portion ofthe second high-voltage electrically conductive conduit with a pluralityof ferrules; overlaying and fixing the plurality of ferrules with aplurality of ring collars; mechanically and electrically joining thefirst exposed region and the second exposed region in a junction; andenclosing and electromagnetically shielding the junction between thefirst high-voltage electrically conductive conduit and the secondhigh-voltage electrically conductive conduit using a splice shield fixedto the plurality of ring collars.
 2. The method of claim 1, wherein thefirst exposed region and the second exposed region are mechanically andelectrically joined by ultrasonic welding.
 3. The method of claim 1,further comprising overlaying a portion of a first external insulativecover, a first braided sleeve, and a first inner insulative layer in thefirst high-voltage electrically conductive conduit with the plurality offerrules and overlaying a portion of a second external insulative cover,a second braided sleeve, and a second inner insulative layer in thesecond high-voltage electrically conductive conduit with the pluralityof ferrules.
 4. The method of claim 3, wherein the forming of the firstexposed region further comprises removing the first inner insulativelayer, the first braided sleeve, and the first external insulative coverfrom the first high-voltage electrically conductive conduit to definethe first exposed region and the forming of the second exposed regionfurther comprises removing the second inner insulative layer, the secondbraided sleeve, and the second external insulative cover from the secondhigh-voltage electrically conductive conduit to define the secondexposed region.
 5. The method of claim 3, further comprising positioninga first of the plurality of ferrules over the first external insulativecover at a location adjacent to the exposed first braided sleeve,folding the exposed first braided sleeve on the first conduit over thefirst of the plurality of ferrules, and arranging a first of theplurality of ring collars over the folded first exposed braided sleeveand positioning a second of the plurality of ferrules over the secondexternal insulative cover at a location adjacent to the exposed secondbraided sleeve, folding the second exposed braided sleeve on the secondhigh-voltage electrically conductive conduit over the second of theplurality of ferrules, and arranging a second of the plurality of ringcollars over the folded second exposed braided sleeve.
 6. The method ofclaim 5, further comprising crimping the first and second of theplurality of ring collars to the respective first and second of theplurality of ferrules, wherein the folded first exposed braided sleeveis disposed between the first of the plurality of ring collars and thefirst of the plurality of ferrules, and the folded second exposedbraided sleeve is disposed between the second of the plurality of ringcollars and the second of the plurality of ferrules.
 7. The method ofassembling a high-voltage splice device of claim 1, further comprisingclamping or crimping the plurality of ring collars over the plurality offerrules.
 8. The method of claim 1, further comprising positioning aprotective cover over the plurality of ferrules and the plurality ofring collars and beneath the splice shield and protecting the junctionfrom moisture and external contaminants.
 9. The method of claim 1,further comprising connecting a third electrically conductive conduitwith the first high-voltage electrically conductive conduit and thesecond high-voltage electrically conductive conduit.
 10. A method ofassembling a splice device comprising: overlaying a plurality offerrules along a portion of a first electrically conductive conduit anda portion of a second electrically conductive conduit; overlaying andfixing a plurality of ring collars to the plurality of ferrules; fixinga splice shield to the plurality of ring collars; andelectromagnetically shielding a junction defined between the firstelectrically conductive conduit and a portion of the second electricallyconductive conduit with the splice shield; wherein each of the pluralityof ferrules includes a flanged portion acting as a stop which directlycontacts the splice shield to retain the splice shield on the ringcollars.
 11. The method of claim 10, further comprising forming thejunction defined between the first electrically conductive conduit andthe second electrically conductive conduit by ultrasonically welding afirst exposed region defined by a first conductive core of the firstelectrically conductive conduit to a second exposed region defined by asecond conductive core of the second electrically conductive conduit.12. The method of claim 10, further comprising enclosing the junctiondefined between the first electrically conductive conduit and the secondelectrically conductive conduit with the splice shield.
 13. The methodof claim 10, further comprising mechanically securing the firstelectrically conductive conduit and second electrically conductiveconduit together with the splice shield.
 14. The method of claim 10,wherein the first electrically conductive conduit and the secondelectrically conductive conduit are each high-voltage electricallyconductive conduits, the first electrically conductive conduit having across-sectional area of greater than or equal to approximately 70 mm²and the second electrically conductive conduit having a cross-sectionalarea of greater than or equal to approximately 50 mm².
 15. The method ofclaim 10, wherein the splice shield is formed from metal.
 16. The methodof claim 10, wherein the plurality of ferrules and the plurality of ringcollars are each formed from metal.
 17. A method for assembling a splicedevice comprising: fixing a splice shield to a first electricallyconductive conduit and to a second electrically conductive conduit at alocation covering a bond formed between the first electricallyconductive conduit and a portion of the second electrically conductiveconduit; mechanically securing the first electrically conductive conduitand the second electrically conductive conduit together with the spliceshield; and electromagnetically shielding the bond from an externalenvironment with the splice shield; wherein the splice shield includes aplurality of ferrules, each of the plurality of ferrules having aflanged portion acting as a stop which directly contacts the spliceshield to retain the splice shield on the first electrically conductiveconduit and the second electrically conductive conduit.
 18. The methodof claim 17, further comprising ultrasonically welding a first exposedregion defined by a first conductive core of the first electricallyconductive conduit to a second exposed region defined by a secondconductive core of the second electrically conductive conduit to formthe bond between the first electrically conductive conduit and thesecond electrically conductive conduit.
 19. The method of claim 18,further comprising: overlaying and fixing a plurality of ring collars tothe plurality of ferrules; overlaying a portion of a first externalinsulative cover, a first braided sleeve, and a first inner insulativelayer of the first electrically conductive conduit with one or more ofthe plurality of ferrules; and overlaying a portion of a second externalinsulative cover, a second braided sleeve, and a second inner insulativelayer of the second high-voltage electrically conductive conduit withone or more of the plurality of ferrules.
 20. The method of claim 19,further comprising removing the first inner insulative layer, the firstbraided sleeve, and the first external insulative cover from the firstelectrically conductive conduit to define the first exposed region andremoving the second inner insulative layer, the second braided sleeve,and the second external insulative cover from the second high-voltageelectrically conductive conduit to define the second exposed region.